Methods and systems for pallet sizing and pucking

ABSTRACT

A pharmaceutical order filling system uses pucks disposed on a pallet to accommodate a plurality of container sizes into which pharmaceuticals can be dispensed. An order processing device receives a pharmaceutical order and identifies a size of container into which a pharmaceutical in the pharmaceutical order should be dispensed. A pallet sizing and pucking device is configured: to configure a pallet with a plurality of pucks adapted to accommodate containers and to configure the pucks on a pallet in a manner that will facilitate efficient fulfillment of the pharmaceutical order.

FIELD

The present application relates generally to the technical field relatesto automated filling centers. In a specific example, the presentapplication may relate to a high volume fulfillment center, e.g., a highvolume pharmacy and to systems and devices used in filling prescriptionsand prescription orders at a high volume pharmacy.

BACKGROUND

A high-volume pharmacy may process and fill a large number ofprescriptions and prescription orders. Automated systems may be used bya high-volume pharmacy to process and fulfill prescriptions. Theautomated systems may include enabled transportation of empty, filled,and/or closed containers to various areas in the pharmacy.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of an example system, according to an exampleembodiment;

FIG. 2 is a block diagram of an example pallet sizing and pucking devicethat may be deployed within the system of FIG. 1, according to anexample embodiment;

FIG. 3 is a top view of a pallet that includes containers and pucks thatmay be deployed within the system of FIG. 1, according to an exampleembodiment;

FIG. 4 is a cross sectional view of the pallet of FIG. 3, at line 4 ofFIG. 3, according to an example embodiment;

FIG. 5 is a perspective view of the pallet of FIG. 3, according to anexample embodiment;

FIG. 6 is an exploded view of a portion of the pallet of FIG. 3,according to an example embodiment;

FIG. 7 is a top view of a pucking station, according to an exampleembodiment, according to an example embodiment;

FIG. 8 is a perspective view of the pucking station of FIG. 7, accordingto an example embodiment;

FIG. 9 is a partial, perspective view of the pucking station of FIG. 7,according to an example embodiment;

FIG. 10 is a perspective view of a gripper head that may be deployedwithin the pucking station of FIG. 7, according to an exampleembodiment;

FIG. 11 is top view of a pallet sizing and pucking subsystem that may bedeployed within the pallet sizing and pucking device of FIG. 2,according to an example embodiment;

FIG. 12 is a perspective view of the pallet sizing and pucking subsystemof FIG. 11, according to an example embodiment;

FIG. 13 is a block diagram of an example control subsystem that may bedeployed in the pallet sizing and pucking device of FIG. 3, according toan example embodiment;

FIG. 14 is an example process flow illustrating a method of controllingthe operation of a pallet and pucking device, according to an exampleembodiment;

FIG. 15 is an example process flow illustrating a method of configuringa pallet, according to an example embodiment; and

FIG. 16 is a block diagram of a machine in the example form of acomputer system within which a set of instructions for causing themachine to perform any one or more of the methodologies discussed hereinmay be executed or stored.

DETAILED DESCRIPTION

Example systems and methods for pallet sizing and pucking are described.In the following description, for purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of example embodiments. It will be evident, however, toone of ordinary skill in the art that embodiments of the invention maybe practiced without these specific details.

Generally, a prescription order is generated for a high volume pharmacy.The prescription order may include more than one prescription drug forfulfillment. Each prescription drug in a prescription order is an ordercomponent of the prescription order. Generally, the order components arepill bottles or other containers and packaging having a quantity of aprescription drug therein.

These containers may be transported throughout portions of the pharmacyby use of pallets containing a number of cavities. Pucks may be placedin these cavities of the pallet that are differently sized and shapedreceptacles to accommodate containers of differing sizes. Thearrangement of pucks in a pallet may be determined based onprescriptions or prescription orders.

FIG. 1 is a block diagram of an example system 100, according to anexample embodiment. While the system 100 is generally described as beingdeployed in a high volume pharmacy (e.g., a mail order pharmacy, adirect delivery pharmacy, an automated pharmacy, and the like), thesystem 100 may otherwise be deployed. The system 100 may include anorder processing device 102 in communication with a benefit managerdevice 106 over a network 104. Additional devices which may be incommunication with the benefit manager device 106 and/or the orderprocessing device 102 over network 104 include: database(s) 108 whichmay store one or more than one of order data 110, member data 112,claims data 114, drug data 116, prescription data 118, and plan sponsordata 120; pallet sizing and pucking device(s) 122; loading device(s)124; inspect device(s) 126; unit of use device(s) 128; automateddispensing device(s) 130; manual fulfillment device(s) 132; reviewdevice(s) 134; imaging device(s) 136; cap device(s) 138; accumulationdevice(s) 140; literature device(s) 141; packing device(s) 142; and unitof use packing device(s) 144. The system 100 may also include additionaldevices, which may communicate with each other over network 104 ordirectly.

The order processing device 102 may receive information aboutprescriptions being filled at a pharmacy in which the order processingdevice 102 is deployed. In general, the order processing device 102 is adevice located within or otherwise associated with a pharmacy locationto enable fulfillment of a prescription by dispensing prescriptiondrugs. In some embodiments, the order processing device 102 may be adevice separate from a pharmacy that enables communication with otherdevices located within a pharmacy. For example, the order processingdevice 102 may be in communication with another order processing device102 and/or other devices 122-144 located with a pharmacy. In someembodiments, an external pharmacy order processing device 102 may havelimited functionality (e.g., as operated by a patient requestingfulfillment of a prescription drug) when an internal pharmacy orderprocessing device 102 may have greater functionality (e.g., as operatedby a pharmacy).

The order processing device 102 may track a prescription order as it isfulfilled. A prescription order may include one or more than oneprescription to be filled by the pharmacy. The order processing device102 may make pharmacy routing decisions and/or order consolidationdecisions for a prescription order. The pharmacy routing decisionsinclude what device or devices in the pharmacy are responsible forfilling at least a portion of the prescription order, where the orderconsolidation decisions include whether portions of a prescription orderor multiple prescription orders should be shipped together for a patientor a patient family. The order processing device 102 may operate on itsown or in combination with the benefit manager device 106. The orderprocessing device 102 may track and/or schedule the literature or otherpaperwork associated with each order or multiple prescription ordersthat are being shipped together.

Examples of the devices 102, 106 include a set-top box (STB), a receivercard, a mobile telephone, a personal digital assistant (PDA), a displaydevice, a portable gaming unit, a tablet, and a computing system;however other devices may also be used. For example order processingdevice 102 may include a mobile electronic device, such an IPHONE orIPAD device by Apple, Inc. mobile electronic devices powered by ANDROIDby Google, Inc. and a BLACKBERRY device by Blackberry Limited. Thedevices 102, 106 may also include other computing devices, such asdesktop computing devices, notebook computing devices, netbook computingdevices, gaming devices, servers, and the like. The devices 102, 106 mayinclude circuitry, a processor, a memory to store data and instructions,and communication functionality. Other types of electronic devices thatcan use rules and instructions to execute various functions may also beused.

Examples of the network 104 include Mobile Communications (GSM) network,a code division multiple access (CDMA) network, 3^(rd) GenerationPartnership Project (3GPP), an Internet Protocol (IP) network, aWireless Application Protocol (WAP) network, a WiFi network, or an IEEE802.11 standards network, as well as various combinations thereof. Thenetwork 104 may include optical communications. The network 104 may be alocal area network or a global communication network, such as theInternet. Other conventional and/or later developed wired and wirelessnetworks may also be used. In some embodiments, the network 104 mayinclude a prescribing network such as the electronic prescribing networkoperated by Surescripts of Arlington, Va.

The benefit manager device 106 is a device operated by an entity atleast partially responsible for creation and/or management of thepharmacy or drug benefit. While this benefit manager operating thebenefit manager device 106 is typically a pharmacy benefit manager(PBM), other entities may operate the benefit manager device 106 eitheron behalf of themselves, the PBM, or another entity. For example, thebenefit manager may be operated by a health plan, a retail pharmacychain, a drug wholesaler, a data analytics or other type ofsoftware-related company, or the like. In some embodiments, a PBM thatprovides the pharmacy benefit may also provide one or more than oneadditional benefits including a medical or health benefit, a dentalbenefit, a vision benefit, a wellness benefit, a radiology benefit, apet care benefit, an insurance benefit, a long term care benefit, anursing home benefit, and the like. The PBM may, in addition to its PBMoperations, operate one or more than one pharmacy. The pharmacies may beretail pharmacies, mail order pharmacies, or otherwise.

Some of the operations of the PBM that operates the benefit managerdevice 106 may include the following. A member (or a person on behalf ofthe member) of a pharmacy benefit plan administered by or through thePBM attempts to obtain a prescription drug at a retail pharmacy locationwhere the member can obtain drugs in a physical store from a pharmacistor pharmacist technician, or in some instances through mail order drugdelivery from a mail order pharmacy location. The member may also obtaina prescription drug directly or indirectly through the use of a machine,such as a kiosk, vending unit, mobile electronic device, or a differenttype of mechanical, electrical, electronic communication device, and/orcomputing device.

The member may have a co-pay for the prescription drug that reflects anamount of money that the member is responsible to pay the pharmacy forthe prescription drug. The money paid by the member to the pharmacy maycome from the personal funds of the member, a health savings account(HSA) of the member or the member's family, a health reimbursementarrangement (HRA) of the member or the member's family, a flexiblespending accounts (FSA) of the member or the member's family, or thelike. An employer of the member may directly or indirectly fund orreimburse the member or an account of the member for the co-pay.

The amount of the co-pay paid by the member may vary by the benefit planof a plan sponsor or client with the PBM. The member's co-pay may bebased on a flat co-pay (e.g., $10), co-insurance (e.g., 10%), and/or adeductible (e.g., for first $500 of annual prescription drug spend) forcertain prescription drugs, certain types and/or classes of prescriptiondrugs, and/or all prescription drugs.

In certain instances, the member may not pay the co-pay or may only payfor a portion of a co-pay for a prescription drug. For example, if theusual and customary cost for a generic version of a prescription drug is$4, and the member's flat co-pay is $20 for the prescription drug, themember may only pay $4 to receive the prescription drug. In anotherexample involving a worker's compensation claim, no co-pay may be due bythe member for the prescription drug. The co-pay may also vary based onthe delivery channel used to receive the prescription drug. For example,the co-pay for receiving prescription drug from a mail order pharmacylocation may be less than the co-pay for receiving prescription drugfrom a retail pharmacy location.

In conjunction with receiving the co-pay (if any) from the member anddispensing the prescription drug to the member, the pharmacy submits aclaim to the PBM for the prescription drug. The PBM may perform certainadjudication operations including verifying the eligibility of themember, reviewing an applicable formulary of the member to determineappropriate co-pay, coinsurance, and deductible for the prescriptiondrug, and performing a drug utilization review (DUR) on the member. ThePBM then provides a response to the pharmacy following performance of atleast some of the aforementioned operations. As part of theadjudication, the plan sponsor (or the PBM on behalf of the plansponsor) ultimately reimburses the pharmacy for filling the prescriptiondrug when the prescription drug was successfully adjudicated. Theaforementioned adjudication operations generally occur before the co-payis received and the prescription drug dispensed. However, the operationsmay occur simultaneously, substantially simultaneously, or in adifferent order. In addition, more or less adjudication operations maybe performed as at least part of the adjudication process.

The amount of reimbursement paid to the pharmacy by a plan sponsorand/or money paid by the member may be based at least in part on thetype of pharmacy network in which the pharmacy is included. Otherfactors may be used to determine the amount in addition to the type ofpharmacy network. For example, if the member pays the pharmacy for theprescription without using the prescription drug benefit provided by thebenefit manager, the amount of money paid by the member may be higherand the amount of money received by the pharmacy for dispensing theprescription drug and for the prescription drug itself may be higher.Some or all of the foregoing operations may be performed by executinginstructions on the benefit manager device 106 and/or an additionaldevice.

In some embodiments, at least some of the functionality of the orderprocessing device 102 may be included in the benefit manager device 106.The order processing device 102 may be in a client-server relationshipwith the benefit manager device 106, a peer-to-peer relationship withthe benefit manager device 106, or in a different type of relationshipwith the benefit manager device 106.

The order processing device 102 and/or the benefit manager device 106may be in communication directly (e.g., through local storage orpeer-to-peer connection(s)) and/or through the network 104 (e.g., in acloud configuration or software-as-a-service) with a database 108 (e.g.,as may be retained in memory or otherwise). The database 108 may bedeployed on the order processing device 102, the benefit manager device106, on another device of the system 100, or otherwise. The database 108may store order data 110, member data 112, claims data 114, drug data116, prescription data 118, and/or plan sponsor data 120. Other data maybe stored in the database 108.

The order data 110 may include data related to the order ofprescriptions including the type (e.g., drug name and strength) andquantity of each prescription in a prescription order. The order data110 may also include data used for completion of the prescription, suchas prescription materials and/or the type and/or size of container inwhich the drug is or is preferably dispensed. In general, prescriptionmaterials are a type of order materials that include an electronic copyof information regarding the prescription drug for inclusion with orotherwise in conjunction with the fulfilled prescription. Theprescription materials may include electronic information regarding druginteraction warnings, recommended usage, possible side effects,expiration date, date of prescribing, or the like. The order data 110may be used by a high volume fulfillment center to fulfill a pharmacyorder.

In some embodiments, the order data 110 includes verificationinformation associated with fulfillment of the prescription in thepharmacy. For example, the order data 110 may include videos and/orimages taken of (i) the prescription drug prior to dispensing, duringdispensing, and/or after dispensing, (ii) the prescription container(e.g., a prescription bottle and sealing lid) used to contain theprescription drug prior to dispensing, during dispensing, and/or afterdispensing, (iii) the packaging and/or packaging materials used to shipor otherwise deliver the prescription drug prior to dispensing, duringdispensing, and/or after dispensing, and/or (iv) the fulfillment processwithin the pharmacy. Other type of verification information such as barcode data read from pallets used to transport prescriptions within thepharmacy may also be stored as order data 110.

The member data 112 includes information regarding the membersassociated with the benefit manager. The information stored as memberdata 112 may include personal information, personal health information,protected health information, and the like. Examples of the member data112 include name, address, telephone number, e-mail address,prescription drug history, and the like. The member data 112 may includea plan sponsor identifier that identifies the plan sponsor associatedwith the member and/or a member identifier that identifies the member tothe plan sponsor. The member data 112 may include a member identifierthat identifies the plan sponsor associated with the patient and/or apatient identifier that identifies the patient to the plan sponsor. Themember data 112 may also include, by way of example, dispensationpreferences such as type of label, type of cap, message preferences,language preferences, or the like.

The member data 112 may be accessed by various devices in the pharmacy,e.g., the high volume fulfillment center, to obtain information utilizedfor fulfillment and shipping of prescription orders. In someembodiments, an external order processing device 102 operated by or onbehalf of a member may have access to at least a portion of the memberdata 112 for review, verification, or other purposes.

In some embodiments, the member data 112 may include information forpersons who are patients of the pharmacy but are not members in abenefit plan being provided by the benefit manager. For example, thesepatients may obtain drug directly from the pharmacy, through a privatelabel service offered by the pharmacy, the high volume fulfillmentcenter, or otherwise. In general, the use of the terms member andpatient may be used interchangeably herein.

The claims data 114 includes information regarding pharmacy claimsadjudicated by the PBM under a drug benefit program provided by the PBMfor one, or more than one, plan sponsors. In general, the claims data114 includes an identification of the client that sponsors the drugbenefit program under which the claim is made, and/or the member thatpurchased the prescription drug giving rise to the claim, theprescription drug that was filled by the pharmacy (e.g., the nationaldrug code number), the dispensing date, generic indicator, GPI number,medication class, the cost of the prescription drug provided under thedrug benefit program, the copay/coinsurance amount, rebate information,and/or member eligibility. Additional information may be included.

In some embodiments, other types of claims beyond prescription drug maybe stored in the claims data 114. For example, medical claims, dentalclaims, wellness claims, or other type of health care-related claims formembers may be stored as a portion of the claims data 114.

In some embodiments, the claims data 114 includes claims that identifythe members with whom the claims are associated. In some embodiments,the claims data 114 includes claims that have been de-identified (e.g.,associated with a unique identifier but not with a particular,identifiable member).

The drug data 116 may include drug name (e.g., technical name and/orcommon name), other names by which the drug is known by, activeingredients, an image of the drug (e.g., in pill form), and the like.The drug data 116 may include information associated with a singlemedication or multiple medications.

The prescription data 118 may include information regardingprescriptions that may be issued by prescribers on behalf of patients,who may be members of the drug benefit plan, for example to be filled bya pharmacy. Examples of the prescription data 118 include patient names,medication or treatment (such as lab tests), dosing information, and thelike. The prescriptions may be electronic prescriptions, paperprescriptions that have been scanned, or otherwise. In some embodiments,the dosing information reflects a frequency of use (e.g., once a day,twice a day, before each meal, etc.) and a duration of use (e.g., a fewdays, a week, a few weeks, a month, etc.).

In some embodiments, the order data 110 may be linked to associatedmember data, claims data 114, drug data 116, and/or prescription data118.

The plan sponsor data 120 includes information regarding the plansponsors of the benefit manager. Examples of the plan sponsor data 120include company name, company address, contact name, contact telephonenumber, contact e-mail address, and the like.

The order processing device 102 may direct at least some of theoperations of the devices 122-144, recited above. In some embodiments,operations performed by one of these devices 122-144 may be performedsequentially, or in parallel with the operations of another device asmay be coordinated by the order processing device 102. In someembodiments, the order processing device 102 tracks a prescription withthe pharmacy based on operations performed by one or more of the devices122-144.

In some embodiments, the system 100 may transport prescription drugcontainers (e.g., between one or more than one of the devices 122-144 inthe high volume fulfillment center) by use of pallets. The pallet sizingand pucking device 122 may configure pucks in a pallet. A pallet may bea transport structure for a number of prescription containers, and mayinclude a number of cavities. A puck may be placed in one or more thanone of the cavities in a pallet by the pallet sizing and pucking device122. A puck may include a receptacle sized and shaped to receive aprescription container. Such containers may be supported by the pucksduring carriage in the pallet and during movement through thefulfillment process. Different pucks may have differently sized andshaped receptacles to accommodate containers of differing sizes, as maybe appropriate for different prescriptions. Pucks allow thestandardization of equipment engaging differently sized drug containerssuch that some automated equipment can move the drug container bygripping the puck that is supporting the container and allow the use ofa standardized pallet that holds a plurality of pucks have a same outerdimension while having differently sized receptacles therein to holddifferently sized drug containers. The pucks may also operate to ensurethat a drug container is centered in a location on the pallet.

The arrangement of pucks in a pallet may be determined by the orderprocessing device 102 based on prescriptions which the order processingdevice 102 decides to launch. In general, prescription orders in theorder database 110 reside in one or more than one queues, and aregenerally launched in a first-in-first-out order. However, the orderprocessing device 102 may use logic and a variety of factors todetermine when and how prescriptions are to be launched. For example,some non-limiting factors which may alter the first-in-first-out orderof launching prescriptions in a pharmacy include the age of the order,whether the order required an outreach to a physician or some otherintervention, whether there are any performance guarantees with plansponsors or members, the available inventory of a given pharmaceuticalin view of existing prescriptions already launched which will requirethat pharmaceutical, the zip code to which the order will be shipped,the workload and volume of various parts of the pharmacy, whether validpaperwork for the order has been received, and/or similar orders for thesame pharmaceutical that are already to be launched. The logic may beimplemented directly in the pallet sizing and pucking device 122, in theorder processing device 102, in both devices 102, 122, or otherwise.Once a prescription is set to be launched, a puck suitable for theappropriate size of container for that prescription may be positioned ina pallet by a robotic arm or pickers. The pallet sizing and puckingdevice 122 may launch a pallet once pucks have been configured in thepallet.

The loading device 124 may load prescription containers into the puckson a pallet by a robotic arm, a pick and place mechanism, or the like.In one embodiment, the loading device 108 has robotic arms or pickers tograsp a prescription container and move it to and from a pallet. Theloading device 124 may also print a label which is appropriate for acontainer that is to be loaded onto the pallet, and apply the label tothe container. The pallet may be located on a conveyor assembly duringthese operations. In an example, the drug containers may be positionedin the pucks by the loading device 124 prior to the pucks being placedin the pallet.

The inspect device 126 may verify that containers in a pallet arecorrectly labeled and in the correct spot on the pallet. The inspectdevice 126 may scan the label on one or more than one container on thepallet. Labels of containers may be scanned or imaged in full or in partby the inspect device 126. Such imaging may occur after the containerhas been lifted out of its puck by a robotic arm, picker, or the like,or may be otherwise scanned or imaged while retained in the puck. Insome embodiments, images and/or video captured by the inspect device 126may be stored in the database 108 as order data 110.

The unit of use device 128 may temporarily store, monitor, label and/ordispense unit of use products. In general, unit of use products areprescription drug products that may be delivered to a patient or memberwithout being repackaged at the pharmacy. These products may includepills in a container, pills in a blister pack, inhalers, and the like.Prescription drug products dispensed by the unit of use device 128 maybe packaged individually or collectively for shipping, or may be shippedin combination with other prescription drugs dispensed by other devicesin the high volume fulfillment center.

The automated dispensing device 130 may include one or more than onedevices that dispense prescription drugs or pharmaceuticals intoprescription containers in accordance with one or multiple prescriptionorders. In general, the automated dispensing device 130 may includemechanical and electronic components with, in some embodiments, softwareand/or logic to facilitate pharmaceutical dispensing that wouldotherwise be performed in a manual fashion by a pharmacist and/orpharmacist technician. For example, the automated dispensing device 130may include high volume fillers that fill a number of prescription drugtypes at a rapid rate and blister pack machines that dispense and packdrugs into a blister pack. Prescription drugs dispensed by the automateddispensing devices 130 may be packaged individually or collectively forshipping, or may be shipped in combination with other prescription drugsdispenses by other devices in the high volume fulfillment center.

The manual fulfillment device 132 may provide for manual fulfillment ofprescriptions. For example, the manual fulfillment device 132 mayreceive or obtain a container and enable fulfillment of the container bya pharmacist or pharmacy technician. In some embodiments, the manualfulfillment device 132 provides the filled container to another devicein the system 100. In an example embodiment, the container may be joinedwith other containers in a prescription order for a patient or member,e.g., on a pallet or at the accumulation device 140. In general, amanual fulfillment may include operations at least partially performedby a pharmacist or pharmacy technician. For example, a person mayretrieve a supply of the prescribed drug, may make an observation, maycount out a prescribed quantity of drugs and place them into aprescription container, or the like. Some portions of the manualfulfillment process may be automated by use of a machine. For example,counting of capsules, tablets, or pills may be at least partiallyautomated (e.g., through use of a pill counter). Prescription drugsdispensed by the manual fulfillment device 132 may be packagedindividually or collectively for shipping, or may be shipped incombination with other prescription drugs dispenses by other devices inthe high volume fulfillment center.

The review device 134 may process prescription containers to be reviewedby a pharmacist for proper pill count, exception handling, prescriptionverification, and the like. Fulfilled prescriptions may be manuallyreviewed and/or verified by a pharmacist, as may be required by state orlocal law. A pharmacist or other licensed pharmacy person who maydispense certain drugs in compliance with local and/or other laws mayoperate the review device 134 and visually inspect a prescriptioncontainer that has been filled with a prescription drug. The pharmacistmay review, verify, and/or evaluate drug quantity, drug strength, and/ordrug interaction concerns, or otherwise perform pharmacist services. Thepharmacist may also handle containers which have been flagged as anexception, such as containers with unreadable labels, containers forwhich the associated prescription order has been cancelled, containerswith defects, and the like. In an example embodiment, the manual reviewcan be performed at the manual station.

The imaging device 136 may image containers once they have been filledwith pharmaceuticals. The imaging device 136 may measure the fill heightof the pharmaceuticals in the container based on the obtained image todetermine if the container is filled to the correct height given thetype of pharmaceutical and the number of pills in the prescription.Images of the pills in the container may also be obtained to detect thesize of the pills themselves and markings thereon. The images may betransmitted to the order processing device 102, and/or stored in thedatabase 110 as part of the order data 110.

The cap device 138 may be used to cap or otherwise seal a prescriptioncontainer. In some embodiments, the cap device 138 may secure aprescription container with a type of cap in accordance with a patientpreference (e.g., a preference regarding child resistance), a plansponsor preference, a prescriber preference, or the like. The cap device138 may also etch a message into the cap or otherwise associate amessage into the cap, although this process may be performed by asubsequent device in the high volume fulfillment center.

The accumulation device 140 accumulates various containers ofprescription drugs in a prescription order. The accumulation device 140may accumulate prescription containers from various devices or areas ofthe pharmacy. For example, the accumulation device 140 may accumulateprescription containers from the unit of use device 128, the automateddispensing device 130, the manual fulfillment device 132, and the reviewdevice 134, at the high volume fulfillment center. The accumulationdevice 140 may be used to group the prescription containers prior toshipment to the member or otherwise.

In some embodiments, the literature device 141 folds or otherwiseprepares the literature for inclusion with a prescription drug order(e.g., in a shipping container). In some embodiments, the literaturedevice 141 that prints the literature may be separate from theliterature device that prepares the literature for inclusion with aprescription order.

The packing device 142 packages a prescription order in preparation forshipping the order. The packing device 142 may box, bag, or otherwisepackage the fulfilled prescription order for delivery. The packingdevice 142 may further place inserts, e.g., literature or other papers,into the packaging received from the literature device 141 or otherwise.For example, bulk prescription orders may be shipped in a box, whileother prescription orders may be shipped in a bag which may be a wrapseal bag. The packing device 142 may label the box or bag with theaddress and a recipient's name. The label may be printed and affixed tothe bag or box, be printed directly onto the bag or box, or otherwiseassociated with the bag or box. The packing device 142 may sort the boxor bag for mailing in an efficient manner (e.g., sort by deliveryaddress). The packing device 142 may include ice or temperaturesensitive elements for prescriptions which are to be kept within atemperature range during shipping in order to retain efficacy orotherwise. The ultimate package may then be shipped through postal mail,through a mail order delivery service that ships via group and/or air(e.g., UPS, FEDEX, or DHL), through delivery service, through a localdelivery service (e.g., a courier service), through a locker box at ashipping site (e.g., an AMAZON locker or a post office box), orotherwise.

The unit of use packing device 144 packages a unit of use prescriptionorder in preparation for shipping the order. The unit of use packingdevice 144 may include manual scanning of containers to be bagged forshipping to verify each container in the order. In an exampleembodiment, the manual scanning may be performed at a manual station.

While the system 100 in FIG. 1 is shown to include single devices 102,106, 122-144 multiple devices may be used. The devices 102, 106, 122-144may be the same type or model of device or may be different device typesor models. When multiple devices are present, the multiple devices maybe of the same device type or models or may be a different device typeor model. The types of devices 102, 106, 122-144 shown in FIG. 1 areexample devices. In other configurations of the system 100, lesser,additional, or different types of devices may be included. Moreover, thesystem 100 shows a single network 104; however, multiple networks can beused. The multiple networks may communicate in series with each other tolink the devices 102, 106, 122-144 or in parallel to link the devices102, 106, 122-144. Multiple devices may share processing and/or memoryresources. The devices 102, 106, 122-144 may be located in the same areaor in different locations. For example, the devices 102, 106, 122-144may be located in a building or set of adjoining buildings. The devices102, 106, 122-144 may be interconnected (e.g., by conveyors), networked,and/or otherwise in contact with one another or integrated with oneanother, e.g., at the high volume fulfillment center. In addition, thefunctionality of a device may be split among a number of discretedevices and/or combined with other devices.

The system 100 may include a single database, or multiple databases,maintained by respective devices operated by or on behalf one or anumber of different persons and/or organizations. The communication mayoccur directly (e.g., through local storage) and/or through the network104 (e.g., in a cloud configuration or software-as-a-service) with adevice that stores a respective database. FIG. 1 represents an exampledeployment of the database 108. However, the system 100 is not limitedto this configuration. The database 108 may be deployed separately fromand/or one or more than one of the devices 102, 106, 122-144, partiallyon more than one of the devices 102, 106, 122-144, or may otherwise bedeployed. The deployment may occur on local storage, remote storage,removable storage, and/or a different type of storage associated withthe devices 102, 106, 122-144. Additionally, while a single database isgenerally depicted, multiple databases may be implemented. In the caseof multiple databases, the different databases may be deployed ondifferent systems, including the devices 102, 106, 122-144 and/or athird-party device or network.

FIG. 2 illustrates the pallet sizing and pucking device 122, accordingto an example embodiment. The pallet sizing and pucking device 122 maybe deployed in the system 100 of FIG. 1, or may otherwise be used. Thepallet sizing and pucking device 122 may include a control subsystem 202and a pallet sizing and pucking subsystem 204. The control subsystem 202may include one or more module and enables the pallet sizing and puckingdevice 122 to control the pallet sizing and pucking subsystem 204, whilethe pallet sizing and pucking subsystem 204 may include one or moredevices and enables the pallet sizing and pucking device 122 with palletsizing and pucking operations (e.g., configuring pucks in a pallet).

FIGS. 3-6 illustrate a pallet 302, according to an example embodiment.The pallet 302 may be used in the system 100 of FIG. 1 (e.g., by thepallet sizing and pucking device 122), or may be otherwise used.

The pallet 302 may be a transport structure for a number of prescriptioncontainers 304, and may include a number of cavities 306. While thepallet 302 is shown to include 25 cavities in a five by five cavityrow/column configuration, other numbers of categories and/or cavityconfigurations of varying shapes, size, and/or dimensions may be used.In some embodiments the pallet may be substantially square and, in suchan embodiment, have a width and length of between approximately 18inches and 22 inches (e.g., approximately 18 inches, 19 inches, 20inches, 21 inches, or 22 inches). In some embodiments, the width and/orlength may be greater than approximately 22 inches or less thanapproximately 18 inches.

In an example embodiment, the cavities 306 are be spaced on the pallet302 such that the center point of adjacent cavities 306 is betweenapproximately 3 inches and 4 inches (e.g., approximately 3 inches, 3.25inches, 3.5 inches, 3.75 inches or 4 inches). In another exampleembodiment, the distance between center points of adjacent cavities 306is more than approximately 4 inches. In yet another example embodiment,the center points of cavities 306 are less than approximately 3 inchesapart.

In an example embodiment, the pallet 302 includes a base 303. The base303 may be formed from multiple components or as a single component. Theheight of the base 303 may be approximately 1 inch. In other exampleembodiments, the combined height of the base 303 and puck nests is lessthan approximately 1 inch or greater than approximately 1 inch. The base303 may be made in whole or in part of metal, such as aluminum. Othersuitable materials may be used for base 303, such as plastic. The pallet302 may include bumpers.

In some embodiments, other carriers beyond the pallet 302 and/or nocarrier may be used to move containers or groups of containers throughthe system 100 or via the pallet sizing and pucking subsystem 204.

The pallet 302 may retain one or more than one containers 304. Acontainer 304 is generally cylindrical and may be of one or a variety ofsizes utilized by a pharmacy for fulfillment of a prescription. Forexample, a pharmacy may have two different sized containers or threedifferent sized containers. Any number of different sized containers maybe used with the pallet 302. The containers 304 may be selected (e.g.,by a pharmacist, by a device in the pharmacy such as the pallet sizingand pucking device 122, or otherwise) based on container sizeavailability, filling considerations of the container 304, cost of thecontainer 304, the size and/or quantity of pharmaceuticals to be placedwithin the container 304, dimensions of the container 304, shippingconsiderations (e.g., cost to ship the prescription drug to a patient)associated with delivery of the container 304, drug handlingconsiderations, or otherwise. While the container 304 is generallydenoted as being used with the pallet 302, the containers 304 mayotherwise be used in the system 100 or in a different system. Shapesbeyond cylindrical shapes may be used for the containers 304. Examplesof other shapes include regular prisms, elliptical cylinders, andcombinations thereof. The receptacle of a puck may be sized to receiveand support the outer shape of the container.

An example configuration of container usage with a pharmacy includes asmall container 304 having a volume of approximately 75 cc, a mediumcontainer 304 having a volume of approximately 120 cc, and a largecontainer 304 having a volume of approximately 200 cc. An exampleconfiguration of container usage with a pharmacy includes a smallcontainer 304 having a volume of 110 cc and a large container 304 havinga volume of approximately 165 cc.

According to an example embodiment, inserts 310 may be placed throughholes 311 of the pallet 302 to form the cavities 306. The inserts 310may be adapted to hold a large container 304 in a generally securemanner. For example, an internal diameter of the insert 310 may beslightly larger than an external diameter of the container 304. FIG. 5,at position X, illustrates a large container 304 disposed within aninsert 310 of the pallet 302, according to an example embodiment. In anexample embodiment, the insert 310 has an internal diameter ofapproximately 2.3 inches and is adapted to receive a 220 cc container304 with an external diameter of between approximately 2.2 inches and2.3 inches, such that the difference between such diameters is betweenapproximately 0.05 inches and approximately 0.1 inches. In anotherexample embodiment, the difference between such diameters is less than0.05 inches or more than approximately 0.1 inches. The insert 310 mayhave an external diameter of approximately 2.7 inches and a height ofapproximately 2.7 inches. Other sizes of inserts 310 may be used inother embodiments.

The inserts 310 may be formed of polymer, plastic, metal, or othersuitable materials. In an example embodiment, the inserts 310 areplastic or polymer.

A puck 308 may be adapted to fit over an insert 310 of the pallet 302.The puck 308 may include a receptacle 312 to accommodate a container 304with a particular size or shape. For example, the insert 310 may fitbetween an interior wall 402 and an exterior wall 404 of a puck 308.

In some embodiments, the pucks 308 may be shaped and configureddifferently to enable retaining containers 304 of different sizes withinan approximately same sized cavity 306 throughout the pallet 302. Theuse of pucks 308 enables different sized containers 304 to be retainedwith the pallet 302 at an approximately uniform height and in anapproximate uniform relative position throughout at least a portion ofthe pallet 302. For example, the pucks 308 may be adapted to both permitmedium and small containers 304, respectively, to be held with relativesecurity in a cavity 306 (e.g., by effectively narrowing the diameter ofthe cavity 306) and to position the tops of all containers 304 withinthe pallet 302 at a substantially uniform height (e.g., by effectivelyraising or lowering the bottom of the cavity 306). In some embodiments,the pucks 308 may also include pucks generally adapted to hold a largecontainer. Through such a configuration, the pallet may be configuredand reconfigured to maintain different size containers in a manner thatenables devices in a pharmacy to generally be agnostic to the containerdimensions in a particular position on the pallet 302.

The receptacle 312 of the puck 308 may adapted to hold a mediumcontainer 304 with relative security. For example, the inner diameter ofthe puck 308 may be between approximately 2 inches and 2.1 inches, theouter diameter of the medium container may be approximately 2 inches,and the difference between such diameters may be between approximately0.05 inches and approximately 0.1 inches. In other example embodiments,the difference between such diameters is less than 0.05 inches or morethan approximately 0.1 inches.

The puck 308 may be adapted to hold a small container 304 with relativesecurity and, when the puck 308 is inserted over the insert 310 of thepallet 302, the cavity 306 is then adapted to hold a small container 304with relative security.

In an example embodiment, a container 304 is held within the pallet 302with relative security when the container 304 will not move relative tothe pallet 302 as the pallet 302 moves throughout a pharmacy unless thecontainer 304 itself is moved by machine or hand.

The pallet 302 may include a radio-frequency identification (RFID) tag314. The RFID tag 314 may be an active RFID tag, such as an active RFIDtag with a close reading range. In some embodiments, the RFID tag 314 isan active, narrowband, read/write RFID tag.

The RFID tag 314 of a particular pallet 302 may store data (or otherwisefacilitate the access of data, e.g., from the database 108) associatedwith the containers 304 that have been, are, and/or will be placedwithin the pallet 302, such as the order data 110, the member data 112,the claims data 114, the drug data 116, the prescription data 118,and/or the plan sponsor data 120 associated with such containers 304.Other data may be stored by and/or or associated with the RFID tag 314,such as the age of the pallet 302, the number of times the pallet 302has been used to transport containers 304 through the system 100, thenumber of errors associated with the pallet 302, and the like. The RFIDtag 314 may also store the position of individual containers on thepallet. In an example embodiment, the RFID tag 314 of the pallet 302,while deployed within a pallet sizing and pucking subsystem 204, storesdata associated with one or more of the following data fields: (1)pallet identifier, (2) container identifier, (3) container properties,(4) pallet route, (5) group status (e.g., status of a group ofcontainers), (6) number of 75 cc pucks on a pallet, and (7) number of120 cc pucks on a pallet.

FIGS. 7-9 illustrate a pucking station 702 according to an exampleembodiment. The pucking station 702 may perform pallet sizing andpucking operations of the pallet sizing and pucking subsystem 204,including one or more than one of the operations of loading the pucks308 onto the pallets 302, unloading the pucks 308 from the pallets 302,and sorting the pucks 308 to be loaded onto the pallets 302 or that havebeen unloaded from the pallets 302. The pallet sizing and puckingoperations of the pallet sizing and pucking subsystem 204 may beperformed to configure the pallet 302 with the pucks 308 so that it canreceive empty containers for filling and/or receive filled containersfor receiving dispensed pharmaceuticals, capping and/or other purposes,such as order consolidation, distribution within the system 100, andpreparation for shipment, among other reasons. Other operations may beperformed by the pucking station 702.

The pucking station 702 may include pucking station RFID readers 704 a,704 b. The pucking station RFID reader 704 a may be an in-bound RFIDreader (e.g., an RFID reader that reads the RFID tag 314 of the pallet302 as it enters the pucking station 702) and the pucking station RFIDreader 704 b may be an out-bound RFID reader (e.g., an RFID reader thatreads the RFID tag 314 of the pallet 302 as it exits the pucking station702). Other types or configurations of RFID readers may be used in otherembodiments. Although two pucking station RFID readers 704 a, 704 b areillustrated in the embodiment of FIG. 7, in other embodiments, thepucking station 302 includes only one pucking station RFID reader. Inyet other embodiments, the pucking station 302 includes more than twopucking station RFID readers. The number of pucking station RFID readersthat may be included in the pucking station 302 may be determined basedon cost of the pucking station RFID readers, functionality of thepucking station RFID readers, a desire of where to monitor the RFID tag314 of the pallet 302 while within the pucking station 302, orotherwise.

The pucking station RFID readers 704 a, 704 b may read data on the RFIDtag 314 of the pallet 302 to obtain data associated with the particularpallet 302, such as such as the order data 110, the member data 112, theclaims data 114, the drug data 116, the prescription data 118, and/orthe plan sponsor data 120. The pucking station RFID readers 704 a, 704 bmay write data to the RFID tag 314 of the pallet 302 (or otherwise causedata to be associated with the pallet 302), such as the order data 110,the member data 112, the claims data 114, the drug data 116, theprescription data 118, and/or the plan sponsor data 120 associated withnew orders (or portions thereof) to be filled by the system 100 usingone or more than one containers 304 that will be placed in the pallet302.

In some embodiments, the pucking station RFID reader 704 a and/or thepucking station RFID reader 704 b reads the following information fromthe RFID tag 314 of the pallet 302 when it enters the pucking station702: the pallet identifier, the number of 75 cc pucks on the pallet 302,and the number of 120 cc pucks on the pallet 302. The pucking stationRFID reader 704 a and/or the pucking station RFID reader 704 b may eraseall contents of the RFID tag 314, other than the pallet identifier, thenumber of 75 cc pucks on the pallet, and the number of 120 cc pucks onthe pallet. The pucking station RFID 704 a and/or the pucking stationRFID reader 704 b reader may write the following data to the RFID tag314: (1) container identifier, (2) container properties, (3) palletroute, (4) group status (i.e., status of a group of containers), (5)number of 75 cc pucks on the pallet 302, and (6) number of 120 cc puckson the pallet 302.

A system conveyor 706 may transport the pallets 302 through some or allof the devices 124-144 within the system 100, such as the pallet sizingand pucking device 122.

As illustrated in FIG. 7, an in-bound lift and transfer unit 708 maydivert or otherwise move the pallet 302 from the system conveyor 706onto a pallet conveyor 710 that delivers the pallets 302 through a frameportion 712 of the pucking station 702. An out-bound lift and transferunit 714 may move the pallet 302 from the pallet conveyor 710 onto thesystem conveyor 706.

Although separate in-bound and out-bound lift and transfer units 708,714 are illustrated in an embodiment shown in FIG. 7, in otherembodiments either or both of the lift and transfer units 708, 714 mayoperate to both move pallets from the system conveyor 706 to the palletconveyor 710 and from the pallet conveyor 710 to the system conveyor706. Furthermore, although two lift and transfer units are illustratedin FIG. 7, fewer or more than two lift and transfer units 708, 714 maybe deployed in other embodiments of the pucking station 702. Thein-bound lift and transfer unit 708 may be adapted to stop the pallet302 when the pucking station 702 is not full and transfer the pallet 302into the pucking station 702 and, when the pucking station 702 is full,to allow the pallet 302 to pass the pucking station 702, e.g., to go onto another pucking station 702, as described below.

Somewhat similarly, the out-bound lift and transfer unit 714 may beadapted to stop the pallet 302 if the configuration of the pallet 302with pucks 308 has been completed at the pucking station 702 and movethe pallet 302 from the pallet conveyor 710 to the system conveyor 706.Alternatively, if the configuration of the pallet 302 with pucks 308 isincomplete, the out-bound lift and transfer unit 714 may allow thepallet 302 to pass through the pucking station 702, e.g., to go intoanother pucking station 702, as described below.

The system conveyor 706 and/or the pallet conveyor 710 may be a chainconveyor or a belt conveyer, e.g., a Bosch TS2 belt-driven conveyor;other types of conveyors may be used for the system conveyor 706 and/orthe pallet conveyor 710, such as a chain conveyor. In some embodiments,the system conveyor 706 and/or the pallet conveyor 710 is a lowfriction, high speed conveyor.

The pallet 302 may be retained in a fixed position within the puckingstation 702 while the pucks 308 are loaded onto or removed from thepallet 302. The pallet conveyor 710 may continue to move under thepallet 302 while it is held in a fixed position.

The puck conveyors 718, 720 may circulate within the pallet sizing andpucking subsystem 204 to deliver the pucks 308 to and from the puckingstation 702. Thus the pucking station 702 may include portions of thepuck conveyors 718, 720 that, in operation, move in one direction (e.g.,toward a first end 721 of the pucking station 702) and portions thatmove in another directions (e.g., toward a second end 722 of the puckingstation 702). The puck conveyors 718, 720 may be chain conveyors or beltconveyors, e.g., Bosch VarioFlow chain conveyors, such as the BoschVarioFlow chain conveyor model number VF90.

The frame portion 712 supports a robot arm 724 within the puckingstation 702, as well as portions of the pallet conveyor 710 and the puckconveyors 718, 720 disposed within the frame portions 712. The robot arm724 may be a low weight bearing, high speed, high accuracy assembly-typerobot arm. In a particular embodiment, the robot arm 724 is a selectivecompliance assembly robot arm (“SCARA”), such as a SCARA robot fromAdept Technology, Inc. Low weight may refer to less than ten pounds,less than five pounds, less than two pounds or less than one pound. Lowweight may refer to at least the weight of a heaviest puck used in thesystem 100. Other types of robot arms may be used for the robot arm 724.The robot arm 724 may perform operations such as removing the pucks 308from the pallet 302 and placing the pucks 308 onto the pallet 302. Otheroperations may be performed by the robot arm 724. In some embodiments,operations of removing the pucks 308 from the pallet 302 or placing thepucks 308 onto the pallet 302 may be performed without the use of therobot arm.

The robot arm 724 may be adapted to grip the pucks 308. The pucks 308may be lifted and moved by the robot arm 724 from the pallets 302,released, and placed onto the puck conveyors 718, 720, such as a portionof the puck conveyors 718, 720 adapted to move toward a first end 721 ofthe pucking station 702. The robot arm 724 may be adapted to selectivelyrelease a first set of pucks 308 (e.g., a set of pucks adapted toreceive a small container) onto one of the puck conveyors 718, 720(e.g., puck conveyor 718) and a second set of pucks 308 (e.g., a set ofpucks adapted to receive a medium container) onto another of the puckconveyors 718, 720 (e.g., puck conveyor 720), thereby sorting the pucks308 removed from the pallet 302 by size. The robot arm 724 may beadapted to selectively remove a first set of pucks 308 (e.g., a set ofpucks adapted to receive a small container) from the pallet 302 andplace the pucks 308 onto one of the puck conveyors 718, 720 (e.g., puckconveyor 718) and to selectively remove a second set of pucks 308 (e.g.,a set of pucks adapted to receive a medium container) onto another puckconveyors 718, 720 (e.g., puck conveyor 720) thereby sorting the pucks308 removed from the pallet 302 by size. The pucks may further be sortedaccording other characteristics of the puck.

The robot arm 724 includes a gripper assembly 726. The gripper assembly726 includes gripper heads 902 a, 902 e, shown as five gripper heads inFIG. 9. The gripper heads 902 a, 902 e may be adapted to grip the pucks308 while on the pallet 302 and may be further adapted to grip the pucks308 while on the puck conveyors 718, 720, thereby enabling the robot arm724 to remove the pucks 308 from the pallet 302 and/or from the puckconveyors 718, 720. The gripper heads 902 a, 902 e may be furtheradapted to release the pucks 308, thereby enabling the robot arm 724 toplace the pucks 308 onto the puck conveyors 718, 720 and/or onto thepallet 302. The gripper heads 902 a, 902 e may be independentlyactuated, pneumatic gripper heads. In an example embodiment, the gripperheads 902 a, 902 e are spring assist closed. In another an exampleembodiment, the gripper heads 902 a, 902 e are spring assist open. Whilefive gripper heads are shown in FIG. 9 including the gripper heads 902a, 902 e, the gripper assembly 726 may include a greater or lessernumber of gripper heads. In some embodiments, the number of gripperheads included in the gripper assembly matches the number of cavities306 in a row or column of the pallet 302.

A stop unit 730, 732 may hold the pucks 308 within a portion of the puckconveyors 718, 720 to form a puck holding area 734, 736 within the puckconveyors 718, 720 (such as a portion of the puck conveyors 718, 720adapted to move toward a second end 722 of the pucking station 702). Thestop unit 730, 732 may be further adapted to open, thereby releasing thepucks 308 from the puck holding area 734, 736 such that the pucks 308can circulate within and through the pallet sizing and pucking subsystem204. Operations of the stop unit 730, 732 may be controlled by thecontrol subsystem 202 or otherwise.

The pucks 308 in the puck holding areas 734, 736 may be gripped, lifted,and moved by the robot arm 724 from the puck holding areas 734, 736 tothe pallet 302 being held within the pucking station 702 and placed intothe cavities 306 of the pallet 302.

In an example embodiment, the pucks 308 adapted to hold one size ofcontainer 304 (e.g., a small container) circulate on a first puckconveyor 718 and another type of pucks 308 adapted to hold another sizeof container 304 (e.g., a medium container) circulate on a second puckconveyors 720. Differing puck to puck conveyor configurations may beused. For example, the pucks 308 circulating on a first puck conveyor718 may be of a different color (e.g., to indicate different drug types,different timing considerations, or the like) than the pucks 308circulating on a second puck conveyor 720. A puck overflow bin 802 maybe adapted to receive excess pucks from puck conveyors 718, 720.

An alignment element 738 may be adapted to align the gripper assembly726 such that the gripper assembly 726 remains aligned with (e.g.,parallel to) the puck conveyors 718, 720 and with the positions (e.g.,cavities 306) of the pallet 302. The alignment element 738 may includecups 740, 742 adapted to fit within the gripper heads 902 a, 902 e. Whenthe gripper heads 902 a, 902 e are disposed onto cups 740, 742, thegripper assembly 726 may align with the positions (e.g., cavities 306)of the pallet 302 and with the puck conveyors 718, 720. The controlsubsystem 202 may control operations of the robot arm 724 such that thegripper assembly 726 is aligned by the alignment element 738periodically, such as each hour, every two hours, daily, or at anotherinterval or intervals. The gripper assembly 726 may be aligned by thealignment element 738 upon a signal generated by an operator request.Operations of the robot arm 724 may be otherwise controlled.

FIG. 10 illustrates a gripper assembly 726 according to an exampleembodiment. The gripper assembly 726 may be deployed in a puckingstation 702 or may be otherwise deployed. The gripper assembly 726includes five gripper heads 902 a, 902 b, 902 c, 902 d, 902 e. Thegripper heads 902 a, 902 b, 902 c, 902 d, 902 e are secured to amounting plate 1002. As illustrated in FIG. 10, the gripper heads 902 a,902 b, 902 c, 902 d, 902 e are engaging pucks 308. In an exampleembodiment, the gripper heads 902 a, 902 b, 902 c, 902 d, 902 e areSeries GRT parallel pneumatic 3-jaw grippers with a 40 mm bore sold byPHD, Inc. Other grippers may be used for the gripper heads 902 a, 902 b,902 c, 902 d, 902 e.

The gripper assembly 726 may be configured to align with a row or columnof the pallet 302. For example the number of gripper heads 902 a, 902 b,902 c, 902 d, 902 e may equal the number of positions (e.g., thecavities 306) on a row or column of the pallet 302 and may be spaced andsized to facilitate association of each gripper head 902 a, 902 b, 902c, 902 d, 902 e with a particular position (e.g., the cavity 306) on thepallet. In some embodiments, the number of gripper heads 902 a, 902 b,902 c, 902 d, 902 e may be more or less than the number of positions ona row or column of the pallet 302. Independently actuated gripper heads902 a, 902 b, 902 c, 902 d, 902 e may be configured, for example, toenable each gripper head 902 a, 902 b, 902 c, 902 d, 902 e to remove apuck 308 from a position (e.g., the cavity 306) on the pallet 302independently of whether other gripper heads 902 a, 902 b, 902 c, 902 d,902 e of the gripper assembly 726 are removing pucks 308 from the palletpositions associated with such gripper heads 902 a, 902 b, 902 c, 902 d,902 e. Thus, during a particular operation, a gripper assembly 726 withfive gripper heads 902 a, 902 b, 902 c, 902 d, 902 e may remove zero,one, two, three, four, or five pucks from a particular row or column ofa pallet. The pucks 308 selected for removal may be in anyconfiguration, e.g., a single puck at any position or two or more pucksadjacent to and/or spaced apart from one another.

Independently actuated gripper heads 902 a, 902 b, 902 c, 902 d, 902 emay be configured, for example, to enable each gripper head 902 a, 902b, 902 c, 902 d, 902 e to select a puck 308 from a puck holding area734, 736 on a puck conveyor 718, 720, independently of whether othergripper heads 902 a, 902 b, 902 c, 902 d, 902 e of the gripper assembly726 are selecting the pucks 308 from the puck holding areas 734, 736.Thus, during a particular operation, the gripper assembly 726 with fivegripper heads 902 a, 902 b, 902 c, 902 d, 902 e may select zero, one,two, three, four, or five pucks from one puck holding area (e.g., thepuck holding area 734 or the puck holding area 736). Additional pucksmay be selected from another puck holding area (e.g., the puck holdingarea 734 or the puck holding area 736). The pucks 308 may be selectedfrom one puck holding area 734, 736 and placed onto the pallet 302 andthen selected from a second puck holding area 734, 736 and placed ontothe pallet 302. In some embodiments, the pucks 308 may be selected fromone puck holding area 734, 736 and then another puck holding area 734,736, and then the pucks 308 selected from both holding areas 734, 736may be place over the inserts 310 on the pallet 302. The pucks 308 maybe selected from only one holding area 734, 736. The pucks 308 selectedfrom the puck holding area 734, 736 may be in any configuration, e.g., asingle puck 308 at any position or two or more pucks 308 adjacent toand/or spaced apart from one another.

FIGS. 11 and 12 illustrate the pallet sizing and pucking subsystem 204according to an example embodiment. The pallet sizing and puckingsubsystem 204 as shown includes three pucking stations 702 a, 702 b, 702c. However, a greater or lesser number of pucking stations 702 may bedeployed in other embodiments of the pallet sizing and pucking subsystem204.

The pucking station 702 may be employed as the pucking stations 702 a,702 b, 702 c of the pallet sizing and pucking subsystem 204. The puckingstations 702 a, 702 b, 702 c, may be configurations of the puckingstation 702 that include the features and functions of the puckingstation 702. In other embodiments, one or more features or components ofthe pucking station 702 may be omitted from the pucking stations 702 a,702 b, 702 c and/or one or more of the pucking stations 702 a, 702 b,702 c may include additional features and/or components. Although threepucking stations 702 a, 702 b, 702 c are shown in the embodiment of thepallet sizing and pucking subsystem 204, in other embodiments, thepallet sizing and pucking subsystem 204 includes less than three or morethan three pucking stations 702 a, 702 b, 702 c. In an exampleembodiment, the pallet sizing and pucking subsystem 204 has one puckingstation 702.

In some embodiments, certain functions of the pallet sizing and puckingsubsystem 204 may performed by fewer than all, including only one of,the pucking stations 702 a, 702 b, 702 c. In an example of such anembodiment, one of the pucking stations 702 a, 702 b, 702 c may unloadpucks 308, another one of the pucking stations 702 a, 702 b, 702 c mayload pucks 308, and yet another one of the pucking stations 702 a, 702b, 702 c may load and unload pucks 308. In another example embodiment,pucks 308 adapted for small containers 304 are loaded and/or unloaded atone of the pucking stations 702 a, 702 b, 702 c and pucks 308 adaptedfor medium containers 304 are loaded and/or unloaded at the others ofthe pucking stations 702 a, 702 b, 702 c. Functions of the pallet sizingand pucking subsystem 204 may be otherwise allocated among the puckingstations 702 a, 702 b, 702 c.

The puck conveyors 718, 720 may circulate the pucks 308 from and throughthe pucking stations 702 a, 702 b, 702 c of the pallet sizing andpucking subsystem 204 and/or transport the pucks 308 to a puck overflowbin 802 a, 802 b, 802 c. The puck conveyors 718, 720 may circulate suchthat some portions move in one direction (e.g., toward the first end721) and some portions move in another direction (e.g., toward thesecond end 722).

Although two puck conveyors 718, 720 of the pallet sizing and puckingsubsystem 204 are illustrated in FIGS. 11 and 12, more or less than twopuck conveyors 718, 720 may be used. For example, a single puck conveyormay be used to transport multiple sizes of pucks 308 or additional puckconveyors may be used to transport additional (e.g., more than two)sizes of pucks 308 or to move larger quantities of pucks 308 within thepallet sizing and pucking subsystem 204 or the pucking station 702.

In-bound and out-bound lift and transfer units 708 a, 708 b, 708 c, 714a, 714 b, 714 c may operate to both move pallets 302 from the systemconveyor 706 to a portion of the pallet conveyor 710 disposed within aparticular pucking station 702 a, 702 b, 702 c and from the palletconveyor 710 (e.g., a portion of the pallet conveyor 710 disposed withinthe pucking station 702 a, 702 b, 702 c) to the system conveyor 706. Thepucking stations 702 a, 702 b, 702 c may each be deployed to configurepucks 308 within a particular pallet 302 and/or one or more of thepucking stations 702 a, 702 b, 702 c may be deployed to cooperativelyconfigure pucks 308 within a particular pallet 302.

For example, the in-bound lift and transfer unit 708 a may move aparticular pallet 302 to a portion of the pallet conveyor 710 disposedwithin the pucking station 702 a, the pallet 302 may be configured bythe pucking station 702 a (e.g., by removing pucks 308 from and/oradding pucks 308 to the pallet), and the pallet 302 may be moved from aportion of the pallet conveyor 710 disposed within the pucking station702 a by the out-bound lift and transfer unit 714 a to the systemconveyor 706, which may then transport the pallet 302 to and/or move thepallet 302 within the system 100, such as to or within the loadingdevice 124, the inspect device 126, the unit of use device 128, theautomated dispensing device 130, the manual fulfillment device 132, thereview device 134, the imaging device 136, the cap device 138, theaccumulation device 140, and/or one or more other devices within thesystem 100. The pucking stations 702 b, 702 c may be similarly deployedand may be deployed to configure a pallet 302 disposed within thatpucking station 702 b, 702 c while another pallet 302 disposed withinanother pucking station (e.g., the pucking station 702 a) is beingconfigured.

In another example, one of the in-bound lift and transfer units (e.g.,the lift and transfer unit 708 a or 708 b) may move a particular pallet302 to a portion of the pallet conveyor 710 disposed within one of thepucking stations (e.g., pucking station 702 a or 702 b), the pallet 302may be partially configured by that pucking station 702 a, 702 b (e.g.,by removing pucks 308 from and/or adding pucks 308 to the pallet 302),the pallet 302 may be moved by the pallet conveyor 710 into one or moreof the other pucking stations (e.g., the pucking station 702 b and/or702 c), the pallet 302 may be further configured by one or more of theother pucking stations 702 b, 702 c, and the pallet 302 may be movedfrom a portion of the pallet conveyor 710 disposed within one of theother pucking stations 702 b, 702 c by the out-bound lift and transferunit 714 b, 714 c to the system conveyor 706, which may then transportthe pallet 302 to and/or move the pallet 302 within the system 100.

After the pallet 302 has been used, e.g., in the system 100 tofacilitate fulfillment of one or more prescriptions (e.g., a first setof prescriptions), the robot arms 724 a, 724 b, 724 c may remove thepucks 308 from pallets 302 retained within the pucking stations 702 a,702 b, 702 c and place the pucks 308 on the puck conveyors 718, 720. Asthe pallet 302 is ready to be used, e.g., in the system to facilitatefulfillment of one or more prescriptions (e.g., a second set ofprescriptions), the robot arms 724 a, 724 b, 724 c may remove the pucks308 from puck holding areas 734 a, 734 b, 734 c, 736 a, 736 b, 736 c andplace them onto the pallets 302 retained within the pucking stations 702a, 702 b, 702 c.

FIG. 13 illustrates an example control subsystem 202 that may bedeployed in the order processing device 102, the pallet sizing andpucking device 122, or otherwise deployed in the system 100. One or moremodules are communicatively coupled and included in the controlsubsystem 202 to enable control of the pallet sizing and puckingoperations of the pallet sizing and pucking device 122. The modules ofthe control subsystem 202 that may be included are an orderprioritization module 1302, the pallet history module 1304, the palletselection module 1306, and the pallet configuration module 1308. Othermodules may also be included.

In some embodiments, the modules of the control subsystem 202 may bedistributed so that some of the modules are deployed in order processingdevice 102 and some modules are deployed in the pallet sizing andpucking device 122. In one embodiment, the modules are deployed inmemory and executed by a processor coupled to the memory. Thefunctionality of the modules may be executed in circuitry implementinginstructions or in computing systems. The functionality contained withinmodules 1302-1308 may be combined into a lesser number of modules,further divided among a greater number of modules, or redistributedamong existing modules. Other configurations including the functionalityof modules 1302-1308 may be used. A module may include hardware,software and combinations thereof.

The order prioritization module 1302 may select orders (or portions oforders) to be filled using the pallets 302 to transport the containers304 (e.g., through one or more than one of the devices 122-142 of thesystem 100). Orders may be selected by the order prioritization module1302 based on factors such as the order in which the prescription wasreceived in the pharmacy relative to other prescriptions, the age of theorder (e.g., how long the prescription has been in the pharmacy),whether the order and/or the prescription required an outreach to aphysician, an intervention or outreach to the patient, or otherwise,whether there are any performance guarantees with plan sponsors ormembers, the available inventory of a given pharmaceutical in view ofexisting prescriptions already launched which will utilized thatpharmaceutical, the zip code to which the order will be shipped, theworkload and volume of various parts of the pharmacy, whether validpaperwork for the order has been received, similar orders for the samepharmaceutical that are already to be launched, and the like. Thefactors may be weighted the same or differently. Other factors may beemployed in selection of orders or portions of orders by the orderprioritization module 1302.

The pallet history module 1304 may accesses data, such as the order data110, the member data 112, the claims data 114, the drug data 116, theprescription data 118, and/or the plan sponsor data 120, associated witha particular pallet 302, as such pallet 302 has been deployed in thesystem 100 for a particular period of time or set of tasks. For example,data associated with a particular pallet 302 may be limited to dataassociated with a single run through the system 100. Data may beaccessed from the RFID tag 314 of the pallet 302 and/or from thedatabase 108, for example. Based on such data, the pallet history module1304 may identify the pallet 302 as having been associated with fillingerrors (such as errors associated with misplacement or misalignment ofcontainers) and, based on such identification, may control operations ofthe pallet sizing and pucking subsystem 204 and/or other devices withinthe system 100 to, for example, cause the pallet 302 to be removedthrough the inspect device 126 or otherwise, or otherwise generate analert to trigger an inspection of the pallet 302. The pallet historymodule 1304 may identify the pallet 302 as having circulated through oneor more devices (e.g., one or more than one of devices 122-142) in thesystem 100 a pre-determined number of times (e.g., 50 times, 100 times,150 times, or 200 times) and, based on such identification may causemaintenance procedures to be applied to the pallet 302, such asapplication of an air blast or other cleaning procedures. The pallethistory module 1304 may identify the configuration of the pallet,including the number of pucks 308 of each size on the pallet 302, as itenters a pucking station 702 a, 702 b, 702 c.

The pallet selection module 1306 may determine which order or orders (orportion or portions thereof) in the queue will be filled using aparticular pallet 302 to transport containers (e.g., through one or morethan one of the devices 122-142). The pallet selection module 1306 maycause the pucking station RFID reader 704 a, 704 b to write data to theRFID tag 314 of the pallet 302. The pallet selection module 1306 mayalso determine to which particular pucking station 702 a, 702 b, 702 cwithin the pallet sizing and pucking subsystem 204 the pallet 302 willbe transported and may control operations of the pallet sizing andpucking subsystem 204 to cause the in-bound lift and transfer device 708a, 708 b, 708 c to transport the pallet 302 into a particular puckingstation 702 a, 702 b, 702 c. The pallet history module 1304 maydetermine that the pallet 302 will bypass the pallet sizing and puckingsubsystem 204 and/or determine route of the pallet 302 through thesystem 100 (e.g., through one or more than one of the devices 122-142).

The pallet selection module 1306 may select orders (or portions oforders) based on prioritization of orders as determined by the orderprioritization module 1302, based on the order history associated withthe pallet 302, e.g., as identified by the pallet history module 1304,and/or may be otherwise selected. For example, orders (or portions oforders) may be selected by the pallet selection module 1306 based on oneor more than one of: (1) a determination that the container requirementsfor such orders will be the same as or similar to the containerrequirements of the orders (or portions thereof) most recently filledusing such the pallet 302 (e.g., that such orders will utilize the sameor similar numbers of small, medium, and large containers); (2) adetermination that the container requirements for such orders will bethe same as or similar to the container requirements of orders (orportions thereof) likely to be subsequently filled using such pallet 302(e.g., that such orders will require the same or similar numbers ofsmall, medium, and large containers); (3) availability of containersizes and/or pucks 308 to adapt such container sizes to the cavities 306of the pallet 302; (4) identification of the automated dispensing device130 at which such containers will be filled; and/or (5) identificationof the cap device 138 at which such containers 304 will be capped. Otherfactors may be employed in determining which orders, or portionsthereof, will be filled using a particular pallet 302. Such factors maybe applied serially or may be otherwise applied. For example orderprioritization module 1302 may present a set of orders (e.g., a set oforders for which more than one pallet 302 may be employed to transportcontainers) and the pallet selection module 1306 may select from suchset of orders (based on one or more of the factors listed above and/orbased on other factors) to identify the member or members of the set tobe filled using the pallet 302 to transport the containers 304.

The pallet configuration module 1308 may associate particular cavities306 within a particular pallet 302 with a particular group or acomponent of an order. Selections may be made by the palletconfiguration module 1308 from the orders (or portions of orders)identified as to be filled using the particular pallet 302, e.g.,selections made by the pallet selection module 1306. For example thepallet configuration module 1308 may associate a first cavity 306 with afirst component of an order (e.g., an order for a particular type andquantity of a pharmaceutical) and may associate a second cavity 306 witha second component of an order. All or less than all of the cavities 306of the pallet 302 may be associated with a particular component of anorder. Association of a particular cavity 306 with a particular ordercomponent may be based on one or more than one of: (1) minimizing thechanges to the current puck configuration of the pallet 302; (2)consolidating sizes of the pucks 308 or the cavities 306 with no puckswithin regions of the pallet 302; and/or (3) optimizing operations atone or more than one of the loading devices 124, the inspect devices126, the automated dispensing devices 130, the manual dispensing devices132, the review devices 134, the imaging devices 136, the cap devices138, the accumulation devices 140, and/or other devices. For example,the cavities 306 may be selected to consolidate containers 304 to becapped with a particular type of cap within one or more than one rows ofthe pallet 302. Other factors may be employed in configuring aparticular pallet 302. In some embodiments, more than one pallet 302 isemployed in connection with filling a particular order, such that acavity 306 on a first pallet 302 may be associated with a firstcomponent of an order and a cavity 306 on a second pallet 302 may beassociated with a second component of an order.

The pallet configuration module 1308 may control operations of a puckingstation 702 to, for example, cause the robot arm 724 to remove one ormore than one of the pucks 308 from the pallet 302 retained within thepucking station 702, to place one or more than one of the pucks 308 ontothe puck conveyors 718, 720, to retrieve one or more of the pucks 308(e.g., one or more pucks 308 of a particular size) from the puck holdingareas 734, 736 and/or place one or more the one of the pucks 308 intothe pallet 302 retained within the pucking station 702. In an embodimentof the pallet sizing and pucking subsystem 204 that includes more thanone pucking stations (e.g., the pucking stations 704 a, 704 b, 704 c),the pallet configuration module 1308 may control the operations of oneor more of the pucking stations 704 a, 704 b, 704 c to configure thepallet 302 with pucks 308 (e.g., as discussed in further detail above).

FIG. 14 illustrates a method of controlling the operation of a puckingstation 702 according to an example embodiment. The method 1400 may beperformed by the pallet sizing and pucking device 122, partially by theorder processing device 102 and partially by the pallet sizing andpucking device 122, or may be otherwise performed.

At block 1402, a pallet 302 containing pucks 308 enters a puckingstation 702 of a pallet sizing and pucking subsystem 204. At block 1404,the existing configuration of the pucks 308 on the pallet 302 isdetermined based on information read from the RFID tag 314. At block1406, content of the RFID tag 314, other than the pallet identifier, thenumber of first-sized pucks, e.g., 75 cc pucks, and the number ofsecond-sized pucks, e.g., 120 cc pucks, is erased. An efficient puckingconfiguration is determined at block 1408, based on the information readfrom the RFID tag 314 and/or new data. Efficient fulfillment of thepharmaceutical orders may include optimizing operations at one or morethan one of the loading device 124, the inspect device 126, theautomated dispensing device 130, the manual fulfillment device 132, thereview device 134, the imaging device 136, the cap device 138, or theaccumulation device 140. In an example embodiment, efficient fulfillmentof the pharmaceutical orders may be based on minimizing the changes to acurrent puck configuration of the pallet 302. In this case, the leastamount of puck movement to and from the pallet 302 is achieved, whichmay result in the pallet 302 spending a least or lesser amount of timeat the pallet sizing and pucking device 122. Orders assigned to thepallet 302 may be determined by the pallet 302 having enoughnon-assigned pucks 308 to fulfill the prescription order. For example,if a prescription order requires two first sized containers and onesecond sized container, then the prescription order may be assigned to asingle pallet 302 that has unassigned pucks 308 for two first containersand one second container. If the pallet 302 has less than two firstcontainer sized pucks 308, then the prescription order may be assignedto another pallet 302 or the pallet configuration must be changed. Thepucks 308 are added to and/or removed from the pallet 302 in accordancewith the determined configuration at block 1410. At block 1412,container information (such as information about the order associatedwith a container to be placed in a particular position on the pallet) ismodified into a format to be written onto the RFID tag 314 by thepucking station RFID tag reader 704 a, 704 b and is written onto theRFID tag 314. At block 1414, the pucking station RFID tag reader 704 a,704 b writes group status information to the RFID tag 314 of the pallet.The pallet 302 is released from the pucking station 702 at block 1416.

FIG. 15 illustrates a method 1500 for configuring a pallet 302 withpucks 308, according to an example embodiment. The method 1500 may beperformed by the pallet sizing and pucking device 122, partially by theorder processing device 102 and partially by the pallet sizing andpucking device 122, or may be otherwise performed.

At block 1502, a pallet 302 holding containers 304 enters a puckingstation 702 of a pallet sizing and pucking subsystem 204. One or morethan one pucks 308 are removed from the pallet 302 and placed onto apuck conveyor 718, 720 at block 1504. At block 1506, the pucks 308 aretransported into the puck holding areas 734, 736 within the puckconveyor 718, 720. The pucks 308 are selected from the puck holdingareas 734, 736 and placed into the pallet 302 at block 1508. After thepallet 302 has been configured at the pucking station 702, it exits thepucking station 702 and the pallet sizing and pucking subsystem 204 atblock 1510.

FIG. 16 shows a block diagram of a machine in the example form of acomputer system 1600 within which a set of instructions may be executedcausing the machine to perform any one or more of the methods,processes, operations, or methodologies discussed herein. The devices102, 106, 122-144 may include the functionality of the one or morecomputer systems 1600.

In an example embodiment, the machine operates as a standalone device ormay be connected (e.g., networked) to other machines. In a networkeddeployment, the machine may operate in the capacity of a server or aclient machine in server-client network environment, or as a peermachine in a peer-to-peer (or distributed) network environment. Themachine may be a server computer, a client computer, a personal computer(PC), a tablet PC, a gaming device, a set-top box (STB), a PersonalDigital Assistant (PDA), a cellular telephone, a web appliance, anetwork router, switch or bridge, or any machine capable of executing aset of instructions sequential or otherwise) that specifies actions tobe taken by that machine. Further, while only a single machine isillustrated, the term “machine” shall also be taken to include anycollection of machines that individually or jointly execute a set (ormultiple sets) of instructions to perform any one or more of themethodologies discussed herein.

The example computer system 1600 includes a processor 1602 (e.g., acentral processing unit (CPU) a graphics processing unit (GPU) or both),a main memory 1604 and a static memory 1606, which communicate with eachother via a bus 1608. The computer system 1600 further includes a videodisplay unit 1610 (e.g., a liquid crystal display (LCD), electronicpaper or a cathode ray tube (CRT)). The computer system 1600 alsoincludes an alphanumeric input device 1612 (e.g., a keyboard), a cursorcontrol device 1614 (e.g., a mouse), a drive unit 1616, a signalgeneration device 1618 (e.g., a speaker) and a network interface device1620.

The drive unit 1616 includes a computer-readable medium 1622 on which isstored one or more sets of instructions (e.g., software 1624) embodyingany one or more of the methodologies or functions described herein. Thesoftware 1624 may also reside, completely or at least partially, withinthe main memory 1604 and/or within the processor 1602 during executionthereof by the computer system 1600, the main memory 1604 and theprocessor 1602 also constituting computer-readable media.

The software 1624 may further be transmitted or received over a network1626 via the network interface device 1620.

While the computer-readable medium 1622 is shown in an exampleembodiment to be a single medium, the term “computer-readable medium”should be taken to include a single medium or multiple media (e.g., acentralized or distributed database, and/or associated caches andservers) that store the one or more sets of instructions. The term“computer-readable medium” shall also be taken to include any mediumthat is capable of storing or encoding a set of instructions forexecution by the machine and that cause the machine to perform any oneor more of the methodologies of the present invention. The term“computer-readable medium” shall accordingly be taken to include, butnot be limited to, solid-state memories, and optical media, and magneticmedia. In some embodiments, the computer-readable medium is anon-transitory computer-readable medium.

The term “based on” or using, as used herein, reflects an open-endedterm that can reflect others elements beyond those explicitly recited.

Certain the systems, apparatus, applications or processes are describedherein as including a number of modules. A module may be a unit ofdistinct functionality that may be presented in software, hardware, orcombinations thereof. When the functionality of a module is performed inany part through software, the module includes a computer-readablemedium. The modules may be regarded as being communicatively coupled.

The inventive subject matter may be represented in a variety ofdifferent embodiments of which there are many possible permutations.

In an example embodiment, an order processing device receivespharmaceutical orders. A pallet sizing and pucking device iscommunicatively coupled to the order processing device. The palletsizing and pucking device configures a pallet with a plurality of pucks.A puck of the plurality of pucks is adapted to receive a containerassociated with a pharmaceutical order. The pallet sizing and puckingdevice is configured to perform puck circulation among a plurality ofpucking stations.

In another example embodiment, an order processing device receives apharmaceutical order and associates a container with the pharmaceuticalorder. A pallet sizing and pucking device is communicatively coupled tothe order processing device and includes a control system to select apallet to use in fulfilling the pharmaceutical order and to select aposition on the pallet to receive a puck adapted to receive thecontainer. The pallet sizing and pucking device also includes a palletsizing and pucking subsystem with a plurality of pucking stations and isconfigured to circulate a plurality of pucks among the pucking stations,to retain the pallet within a pucking station, and to place the puckselected from among the plurality of pucks at the selected position onthe pallet while the pallet is retained in the pucking station.

In yet another example embodiment, a pharmaceutical order processingdevice processes orders to be filled using containers. A pallet sizingand pucking device is communicatively connected to the order processingdevice and includes control subsystem to receive a configurationpreference from the order processing device. The pallet sizing puckingdevice also includes a pallet sizing and pucking subsystem to configurea pallet with pucks adapted to receive the containers according to theconfiguration preference. The pallet sizing and pucking subsystemincludes a puck conveyor to circulate pucks among a plurality of puckingstations, each of which has a robot arm to selectively place the pucksonto the pallet and remove the pucks from the pallet. Each robot armincludes a gripper assembly.

Thus, methods and systems for pallet sizing and pucking have beendescribed. Although embodiments of the present invention have beendescribed with reference to specific example embodiments, it will beevident that various modifications and changes may be made to theseembodiments without departing from the broader spirit and scope of theembodiments of the invention. Accordingly, the specification anddrawings are to be regarded in an illustrative rather than a restrictivesense.

The methods described herein do not have to be executed in the orderdescribed, or in any particular order. Moreover, various activitiesdescribed with respect to the methods identified herein can be executedin serial or parallel fashion. Although “End” blocks are shown in theflowcharts, the methods may be performed continuously.

In the foregoing Detailed Description, it can be seen that variousfeatures are grouped together in a single embodiment for the purpose ofstreamlining the disclosure. This method of disclosure is not to beinterpreted as reflecting an intention that the claimed embodimentsrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive subject matter may lie inless than all features of a single disclosed embodiment. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separate embodiment.

The invention claimed is:
 1. A pharmaceutical order filling systemcomprising: an order processing device to receive pharmaceutical orders;a plurality of pucks including a first group of pucks adapted to receivea first set of containers and a second group of pucks adapted to receivea second set of containers, the containers being from the first set ofcontainers or the second set of containers; and a pallet sizing andpucking device coupled to the order processing device, the pallet sizingand pucking device including a plurality of pucking stations adapted toconfigure a pallet having a plurality of inserts with a plurality ofpucks associated with a pharmaceutical order, wherein the pallet sizingand pucking device includes: a gripper assembly including a plurality ofgripper heads, each gripper head adapted to grip and to release eachpuck of the plurality of pucks, wherein each gripper head is one ofbiased opened and biased closed, wherein each gripper head of theplurality of gripper heads is an independently actuated, pneumaticgripper head adapted to grip and to release each puck of the pluralityof pucks, and wherein the plurality of gripper heads are adapted toalign with a row of inserts of the plurality of inserts; a puck conveyorthat circulates a group of the plurality of pucks among the plurality ofpucking stations, a first puck conveyor adapted to circulate the firstgroup of the plurality of pucks, a second puck conveyor that is adaptedto circulate the second group of the plurality of pucks, and a puckholding area, wherein the puck holding area comprises a portion of thepuck conveyor and a stop unit; and wherein at least one pucking stationof the plurality of pucking stations includes a robot arm, the robot armadapted to selectively place at least one of the pucks onto the palletand to selectively remove at least one of the pucks from the pallet,wherein the robot arm is adapted to selectively remove the puck from thepuck holding area when the puck is gripped by the gripper assembly andto selectively place the puck over an insert of the plurality of insertswhen the puck is released by the gripper assembly, and wherein the robotarm is adapted to selectively place a group of the plurality of pucksonto a row of inserts of the plurality of inserts, each puck being fromat least one of the first group of the plurality of pucks and the secondgroup of the plurality of pucks.
 2. The system of claim 1, wherein aninsert of the row of inserts is substantially cylindrical and has aninternal diameter of approximately 2.3 inches, and wherein each puck ofthe first group of pucks comprises an interior wall and an exterior walland is adapted to receive the insert between the interior wall and theexterior wall of the puck.
 3. The system of claim 1, wherein the secondcontainer is a different size than the first container and wherein eachpuck of the second group of pucks is a different size than each puck ofthe first group of pucks.
 4. The system of claim 3, wherein each puck ofthe first group of pucks is configured to receive a container having avolume of approximately 75 cubic centimeters and each puck of the secondgroup of pucks is configured to receive a container having a volume ofapproximately 120 cubic centimeters.
 5. The system of claim 1, furthercomprising an alignment element configured to fit within a gripper headof the plurality of gripper heads and within an insert of a row ofinserts, wherein the alignment element is adapted to maintain alignmentof the plurality of gripper heads with the row of inserts.
 6. The systemof claim 1, wherein the gripper head is one of spring assist closed andspring assist open.
 7. A system comprising: a pharmaceutical orderprocessing device to process orders to be filled using containers; aplurality of pucks including a first group of the plurality of pucksadapted to receive a first set of containers and a second group of theplurality of pucks adapted to receive a second set of containers; apallet sizing and pucking device communicatively connected to the orderprocessing device, the pallet sizing and pucking device comprising acontrol subsystem to receive a configuration preference from the orderprocessing device; and wherein the pallet sizing pucking device furthercomprises a pallet sizing and pucking subsystem to configure a palletwith pucks from the first group of pucks and the second group of pucksadapted to receive the containers from the first set of containers andthe second group of containers according to the configurationpreference, wherein the pallet sizing and pucking subsystem comprises aplurality of pucking stations, wherein each pucking station of theplurality of pucking stations comprises a robot arm and an alignmentelement, wherein the robot arm is adapted to selectively place at leastone of the pucks onto the pallet and to selectively remove at least oneof the pucks from the pallet, each robot arm comprising a gripperassembly, wherein the alignment element is adapted to fit within agripper head of the gripper assembly and within an insert of a row ofinserts on the pallet, and wherein the alignment element is adapted tomaintain alignment of the gripper head with the row of inserts, andwherein the pallet sizing and pucking subsystem further comprises a puckconveyor adapted to circulate a group of the pucks among the puckingstations.
 8. The system of claim 7, wherein the gripper head is adaptedto grip and to release each puck of the plurality of pucks, wherein thegripper head is one of biased opened and biased closed.
 9. The system ofclaim 7, wherein the gripper head is an independently actuated,pneumatic gripper head adapted to grip and to release each puck of theplurality of pucks.
 10. The system of claim 7, wherein the pallet sizingand pucking subsystem further comprises a first puck conveyor adapted tocirculate the first group of the plurality of pucks and a second puckconveyor adapted to circulate the second group of the plurality ofpucks.
 11. The system of claim 7, wherein the pallet sizing and puckingsubsystem further comprises a puck holding area, wherein the puckholding area comprises a portion of the puck conveyor and a stop unit.12. A pharmaceutical order filling system comprising: an orderprocessing device to receive pharmaceutical orders; a plurality of pucksincluding a first group of pucks adapted to receive a first set ofcontainers and a second group of pucks adapted to receive a second setof containers, the containers being from the first set of containers orthe second set of containers; and a pallet sizing and pucking devicecoupled to the order processing device, the pallet sizing and puckingdevice including a plurality of pucking stations adapted to configure apallet having a plurality of inserts with a plurality of pucksassociated with a pharmaceutical order, wherein the pallet sizing andpucking device includes: a gripper assembly including gripper heads,each gripper head adapted to grip and to release each puck of theplurality of pucks, wherein each gripper head is one of spring assistclosed and spring assist open, wherein each gripper head of theplurality of gripper heads is an independently actuated, pneumaticgripper head adapted to grip and to release each puck of the pluralityof pucks, and wherein the plurality of gripper heads are adapted toalign with a row of inserts of the plurality of inserts; a puck conveyorthat circulates a group of the plurality of pucks among the plurality ofpucking stations, a first puck conveyor adapted to circulate the firstgroup of the plurality of pucks, a second puck conveyor that is adaptedto circulate the second group of the plurality of pucks, and a puckholding area, wherein the puck holding area comprises a portion of thepuck conveyor and a stop unit; and wherein at least one pucking stationof the plurality of pucking stations includes a robot arm, the robot armadapted to selectively place at least one of the pucks onto the palletand to selectively remove at least one of the pucks from the pallet, andwherein the robot arm is adapted to selectively remove the puck from thepuck holding area when the puck is gripped by the gripper assembly andto selectively place the puck over an insert of the plurality of insertswhen the puck is released by the gripper assembly.